4 maximum torque (da.nm - EC) 28.5 engine speed at max. torque (r.p.m.) 3750 turbocharger N/A exchanger N/A injection system one-touch make BOSCH type ME MAIN CHANGES The ES9J4S/L4 engine incorporates the following developments compared with the ES9J4/L3 engine : fitting of a variable timing system, to improve the torque and consumption, consisting of 2 vtc's (variable timing camshaft) located on the intake camshafts, with this variable timing system it is possible to vary the camshafts setting by 15 o new inlet manifold (replacement of the short and long ducts by 6 ducts of equal length) addition of a water/oil heat exchanger on the engine (manual gearbox versions) new flexible engine flywheel which improves driveability by absorbing engine vibrations (manual gearbox versions) new emission control standard L4 obtained by 2 extra pre-catalysers linked to 4 lambda sensors, in addition to the 2 catalytic converters, and a new combustion chamber new multiple jet injectors injection system BOSCH ME7.4.6 for managing eobd and incorporating management of the cooling (FRIC (cooling function integral with the ECU)) addition of a body accelerometer for the eobd function ignition provided by 6 BAC1 model pencil coils presence of a motorised throttle controlled by the engine management ecu NOTE : EOBD : European On Bord Diagnosis : diagnosis of the emission control equipment. 2 - MODIFICATION : EQUIPMENT New audio system amplifierjbl. The role of the audio system amplifier is to give better reception and sound quality. This amplifier is located behind the audio system. 3 - MODIFICATION : ELECTRICAL EQUIPMENT

5 3-1 - MODIFICATION OF HARNESSES The electrical harnesses are undergoing modifications : Refer to the wiring diagram. Removal of the wheel anti-lock braking system harness : the front wheel anti-lock braking system sensors and the ecu are incorporated in the main harness the rear wheel anti-lock braking system sensors are incorporated in the passenger compartment harness FUSE BOX Modifications have appeared to the fusebox and/or the fuses (Refer to the wiring diagram) CONNECTIONS Reverse connector with SICMA 2 connectors.

14 engine speed at max. power (r.p.m.) 6000 maximum torque : EU standards (da.nm) 19.2 engine speed at max. torque (r.p.m.) 4100 injection system high pressure multipoint make SIEMENS type SIRIUS 81 catalytic converter yes Quantity of oil with replacement of the filter cartridge: 4.25 litre(s) MOTOR OPERATION The petrol direct injection engine is controlled by the engine management ecu in line with two operating modes : uniform mixture operation stratified lean mixture operation Uniform mixture operation : the petrol is injected during the inlet phase the gas recirculation rate (egr) is low the engine load is controlled by the throttle housing This operating mode is similar to petrol indirect injection. Stratified lean mixture operation : the petrol is injected just before ignition, during the compression phase, near the spark plug the gas recirculation rate (egr) is high, around 30 % the engine load is controlled by variation of the flow injected the motorised throttle housing is in the open position The high pressure injection pump driven at the end of the camshaft, clutch side, delivers between 70 and 120 bars. The injection rail is fitted with a pressure sensor and a pressure regulator permitting the return of fuel to the high pressure pump inlet to regulate the petrol pressure in the rail.

15 5-4 - ENGINE STRUCTURE The pistons are specific with an adapted bowl at the injector jet.

16 The cylinder head with 4 valves per cylinder and 2 camshafts is specific ; The air inlet pipes (1) are incorporated in the cylinder head, their position is almost vertical. The shape of the piston combined with the position of the air inlet pipes (1) and of the injector (2) create a swirl (inverse tumble) permitting the following actions : ensure that the mixture is uniform during conventional operation (I) direct the small quantity of petrol towards the spark plug during lean mixture operation (II) ENGINE CHECK The engine management assembly is controlled by an ecu SIEMENS of the SIRIUS 81 type. This ecu is fitted with a flash eprom memory. In relation to the EW10J4 engine, this ecu controls the following additional functions : calculation of the engine load engine synchronisation driving pleasure driver's engine torque requirement (input of accelerator pedal position) cruise control exhaust gas emission control

17 braking vacuum management air conditioning cooling requirement air conditioning compressor management electrical energy management can network multiplexing EXHAUST GAS EMISSION CONTROL The exhaust line consists of : (3) exhaust manifold (6) tri-function pre-catalyst fitted with upstream (4) and downstream (9) temperature sensors (5) proportional oxygen sensor upstream of the pre-catalyst (8) denox catalytic converter (7) on/off oxygen sensor at the catalytic converter outlet The temperature sensors permit checking of the effectiveness of the pre-catalyst. The proportional oxygen sensor enables the ecu to adjust the richness of the mixture. Operation in lean mixture mode produces a large quantity of nitrogen oxide (nox) which the pre-catalyst cannot eliminate sufficiently. the role of the catalytic converter is to reduce the amount of nitrogen oxide in the exhaust gas.

21 7-4 - PARTICLE FILTER The particulate emission filter positioned after the catalytic converter traps the particles of carbon which are then burned during the regeneration phases. The additive added to the fuel automatically every time the tank is filled permits lowering of the soot combustion temperature ; The additive reservoir is taken from the 607 (capacity 5 litres). The particulate emission filter is controlled by the engine management ecu and by the diesel additive ecu; its operation is identical to 607. The 4 point clamp between the catalytic converter and the particulate emission filter is specific; the particulate emission filter 406 is shorter than the particulate emission filter 607 (length 9 inches). (13) Upstream pressure sensor. (14) Downstream pressure sensor. (15) Downstream temperature sensor. (16) Upstream temperature sensor.

22 Measuring the upstream/downstream pressure difference permits calculation of the particulate emission filter's soot load. Measuring the temperatures permits checking of the operation during the regeneration phase. Regular maintenance must be carried out every miles kilometres) or at the request of the engine management ecu : maintenance of the particulate emission filter filling of the additive reservoir It is possible to force regeneration using the diagnostic equipment DIAG WARNING : during regeneration, the temperatures at the exhaust line are very high ; the working area must be clear ; do not connect the exhaust gas extraction take-off. 8 - ENGINE DW PLASTIC WATER OUTLET HOUSING The aluminium water outlet housing has been replaced with a plastic water outlet housing on DW10TD - DW10ATED engines.

23 Modified parts : water outlet housing cylinder head degas water pipe exchanger outlet water pipe radiator outlet water pipe heater matrix inlet water pipe fuel unions left front lifting eye style cover fixings The water pipes are only modified at the engine end. Old assembly/new assembly mixtures are not permitted. Parts division will continue to supply the old parts ELECTRIC DIESEL HEATER The diesel heating system previously incorporated in the aluminium water outlet housing has been replaced with an electric diesel heater positioned on top of the engine. 9 - FUEL TANK New fuel circuit: the tank and the filler spout have been modified to meet the requirements of evaporation standard EURO 3 and to permit the installation of the additive reservoir (versions with particulate emission filter). Addition of a switch positioned in the tank pipe transmitting tank cap presence information to an instrument panel warning light.

29 (28) Vacuum valve. (29) Vacuum sensor. (30) Interface accommodating the vacuum sensor and the vacuum valve. (31) Retaining of the vacuum sensor on the interface by bolting. (D) Black section towards the source of the vacuum. (E) White section towards the servo. EW10D engine operation in lean mixture mode (throttle open) does not permit creation of the vacuum necessary for servo-assisted braking. The vacuum level in the servo is monitored by the engine management ecu via a vacuum sensor (23). When the vacuum level in the servo is too low, the engine management ecu closes the throttle (operation in uniform mixture mode) until the vacuum level in the brake servo is sufficient. If the vacuum circuit fails, the engine management ecu positions the throttle to guarantee a sufficient vacuum level.

30 This fault is stored by the engine management ecu but the driver is not informed ADAM EMERGENCY BRAKING ASSISTANCE SYSTEM Introduction of the adam CONTINENTAL TEVES emergency braking assistance system as standard on all engines. Adam: advanced dynamic aid mechanism. The brake servo (32) is fitted with a device permitting reduction of the braking distance in the event of emergency braking. It is a mechanical system permitting 2 operating modes : during slow braking, the servo-assistance ratio is 6 during emergency braking, the servo-assistance ratio is 23 The system is triggered when the power of the pedal (force x speed) exceeds a threshold; this threshold is set at the factory. The master cylinder remains a conventional system (Tandem master cylinder).

31 This system does not require any modification to the brake circuit bleed procedure. Data : F : pedal force P : master cylinder pressure (33) slow braking graph (34) emergency braking graph DISC BRAKES The 406 vehicle is fitted with 4 disc brakes as standard on all models. Reminder : handbrake adjustment must be accompanied by bedding in of the brake linings adjustment of the handbrake and bedding in of the linings must be carried out at each service 13 - EQUIPMENT DYNAMIC STABILITY CONTROL

32 Vehicles fitted with the ES9J4S engine are fitted with esp dynamic stability control as standard. The purpose of the esp dynamic stability control system is to improve active safety in extreme driving conditions (slippery road surface, avoidance manoeuvre...). The esp dynamic stability control ecu controls the following functions : dynamic stability control (ESP) anti-lock brakes (ABS) electronic braking distribution (REF) traction control (ASR) To determine the trajectories, the ecu checks the following information and compares it with models : steering wheel angle sensor (desired trajectory) accelerometer/gyrometer dual-purpose sensor (actual trajectory) front and rear wheel sensors The trajectory is modified by action on : braking (via a pre-charge pump and a hydraulic unit) the torque transmitted to the wheels The asr traction control and esp dynamic stability control functions can be switched off partially by means of a switch to increase the traction of the front wheels. Once they have been switched off by the driver, these functions remain off irrespective of the vehicle speed. 3 warning lights indicate the appearance of a fault in the system.

33 Description of the ESP pre-charge pump hydraulic circuit : (34) reservoir (35) pre-charge pump (36) low pressure pipe (intake) (37) high pressure pipe (discharge) (38) master cylinder It is essential to bleed the esp hydraulic circuit in the following cases : opening of the ESP pre-charge pump hydraulic circuit opening of the circuit between the master cylinder and the hydraulic unit presence of air in the master cylinder periodic replacement of the brake fluid replacement of the brake fluid reservoir Bleeding requires the use of the diagnostic equipment DIAG 2000; the procedure is described in the DIAG AMVAR AUTOMATICALLY ADJUSTED SUSPENSION The amvar suspension option (ES9J4S engine) has been discontinued.

34 AUDIO SYSTEMS New RM2 model radio, made by CLARION with cassette player in the front panel. New RD2 model radio, made by CLARION with CD player in the front panel. This audio equipment is fitted with the automatic speed-related volume adjustment function. These audios are able to run a cd player. In service, the audio equipment and the multifunction display (B or C) must be configured using the DIAG 2000 (This function will become available during the course of the year). The amplifier JBL is available as an option on estate versions. The role of the audio system amplifier is to give better reception and sound quality. The amplifier JBL is secured to the satellite navigation system ecu support TRIP COMPUTER The trip computer is standard on level 1 saloons and estates POWER STEERING Vehicles fitted with the DW10TD engine are fitted with falling output power steering as standard INSTRUMENT PANEL

37 For vehicles equipped with esp, the vehicle speed information is transmitted to the bsi by the esp ecu. For vehicles fitted with abs, the abs ecu (54) transmits the vehicle speed information to the engine management ecu (49) which distributes it on the can network ELECTRICAL EQUIPMENT HARNESS MODIFICATIONS Modification to the electrical harnesses. Front panel harness integrated in main panel CONNECTIONS Front door locks with connector SICMA COOLANT From spare parts organisation number : The cooling circuits are filled with long-life coolant REVKOGEL 2000 or Glysantin G33.

42 The build code number is located at : (C) - (D) or (E) LATER INSTALLATION COUPE

43 The build code number is located at (E), on the front left shock absorber tower. The new tyre pressure label including the build code, the paint code and the serial number, is at (B), on the driver's side.

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